Miller KF824571 Owner's manual

cover 5/94 − ST-133 781-A PRINTED IN USA

Trailblazer® 55D

Read and follow these instructions and all

safety blocks carefully.

Have only trained and qualified persons

install, operate, or service this unit.

Call your distributor if you do not understand

the directions.

Give this manual to the operator.

For help, call your distributor

or: MILLER Electric Mfg. Co., P.O. Box 1079,

Appleton, WI 54912 414-734-9821

OWNER’S

MANUAL

March 1995 Form: OM-456P

Effective With Serial No. KF824571

CC/CV DC Welding Generator

For SMAW And GMAW Welding

350 Amperes, 40 Volts DC/CC At 100% Duty Cycle;

400 Amperes, 36 Volts DC/CV At 100% Duty Cycle

3 kVA/kW AC Auxiliary Power With Overload Protection

Teledyne-Continental TMD-27, Liquid-Cooled, Diesel Engine

Automatic Low Oil Pressure/High Coolant Temperature Shutdown

Glow Plugs For Cold Weather Starting

For Options And Accessories, See Rear Cover

miller_war1 6/95

MILLER’S TRUE BLUE® LIMITED WARRANTY

Effective January 1, 1995

(Equipment with a serial number preface of “KD” or newer)

This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY − Subject to the terms and conditions below, MILLER Elec-

tric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new

MILLER equipment sold after the effective date of this limited warranty is free of de-

fects in material and workmanship at the time it is shipped by MILLER. THIS WAR-

RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR

IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT-

NESS.

Within the warranty periods listed below, MILLER will repair or replace any war-

ranted parts or components that fail due to such defects in material or workman-

ship. MILLER must be notified in writing within thirty (30) days of such defect or fail-

ure, at which time MILLER will provide instructions on the warranty claim proce-

dures to be followed.

MILLER shall honor warranty claims on warranted equipment listed below in the

event of such a failure within the warranty time periods. All warranty time periods

start on the date that the equipment was delivered to the original retail purchaser, or

one year after the equipment is sent to a North American distributor or eighteen

months after the equipment is sent to an International distributor.

1. 5 Years Parts − 3 Years Labor

* Original main power rectifiers

* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Supplies

* Intellitig

* Robots

3. 2 Years — Parts and Labor

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

* Air Compressors

4. 1 Year — Parts and Labor

* Motor Driven Guns

* Process Controllers

* IHPS Power Sources

* Water Coolant Systems

* HF Units

* Grids

* Spot Welders

* Load Banks

* SDX Transformers

* Running Gear/Trailers

* Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)

* Tecumseh Engines

* Deutz Engines (outside North America)

* Field Options

(NOTE: Field options are covered under True Blue® for the remaining

warranty period of the product they are installed in, or for a minimum of

one year — whichever is greater.)

5. 6 Months — Batteries

6. 90 Days — Parts and Labor

* MIG Guns/TIG Torches

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches

* Remote Controls

* Accessory Kits

* Replacement Parts

MILLER’S True Blue® Limited Warranty shall not apply to:

1. Items furnished by MILLER, but manufactured by others, such as engines or

trade accessories. These items are covered by the manufacturer’s warranty, if

any.

2. Consumable components; such as contact tips, cutting nozzles, contactors

and relays or parts that fail due to normal wear.

3. Equipment that has been modified by any party other than MILLER, or equip-

ment that has been improperly installed, improperly operated or misused

based upon industry standards, or equipment which has not had reasonable

and necessary maintenance, or equipment which has been used for opera-

tion outside of the specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER-

CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN

THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies

shall be, at MILLER’S option: (1) repair; or (2) replacement; or, where authorized in

writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replace-

ment at an authorized MILLER service station; or (4) payment of or credit for the

purchase price (less reasonable depreciation based upon actual use) upon return

of the goods at customer’s risk and expense. MILLER’S option of repair or replace-

ment will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a MILLER autho-

rized service facility as determined by MILLER. Therefore no compensation or re-

imbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN

ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE

LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL

DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON-

TRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED

WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND

ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL

THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,

OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN-

CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS

FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty

lasts, or the exclusion of incidental, indirect, special or consequential damages, so

the above limitation or exclusion may not apply to you. This warranty provides spe-

cific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties

or remedies other than as stated herein, and to the extent that they may not be

waived, the limitations and exclusions set out above may not apply. This Limited

Warranty provides specific legal rights, and other rights may be available, but may

vary from province to province.

WHO DO I CONTACT?

For help,

H contact your distributor

For additional information, such as

Technical Manuals (Service And Parts)

Engine Manuals

Circuit And Wiring Diagrams

Process Handbooks

User’s Guides

Distributor Directories

H contact your distributor

To file a claim for loss or damage during

shipment,

H contact the delivering carrier

For assistance in filing or settling claims,

H contact your distributor and/or equipment

manufacturer’s Transportation

Department

Miller Electric Mfg. Co.

H CALL:

414-735-4505

H FAX:

800-637-2348 (in USA), or

414-735-4136 (outside USA)

H WRITE:

Miller Electric Mfg. Co.

P.O. Box 1079

Appleton, WI 54912 USA

Always provide Model Name and Serial or Style Number

OM-456P − 3/95

EMF INFORMATION

The following is a quotation from the General Conclusions Section of

the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields −

Background Paper, OTA-BP-E-53 (Washington, DC: U.S.

Government Printing Office, May 1989): “. . . there is now a very large

volume of scientific findings based on experiments at the cellular

level and from studies with animals and people which clearly

establish that low frequency magnetic fields can interact with, and

produce changes in, biological systems. While most of this work is

of very high quality, the results are complex. Current scientific

understanding does not yet allow us to interpret the evidence in a

single coherent framework. Even more frustrating, it does not yet

allow us to draw definite conclusions about questions of possible risk

or to offer clear science-based advice on strategies to minimize or

avoid potential risks.”

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away as practical.

5. Connect work clamp to workpiece as close to the weld as

possible.

About Pacemakers:

The above procedures are among those also normally

recommended for pacemaker wearers. Consult your doctor for

complete information.

Considerations About Welding And The Effects Of Low Frequency Electric And

Magnetic Fields

NOTE

mod10.1 4/93

TABLE OF CONTENTS

SECTION 1 − SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Volt-Ampere Curves 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Fuel Consumption 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. AC Auxiliary Power 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Selecting A Location And Moving Welding Generator 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Installing Muffler 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Connecting The Battery 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Engine Prestart Checks 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Generator Auxiliary Power System 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Selecting And Preparing Weld Output Cables 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Connecting To Weld Output Terminals 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Remote A/V Receptacle Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Remote 14 Receptacle Or Terminal Strip Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATING THE WELDING GENERATOR 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATING AUXILIARY EQUIPMENT 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. 120 Volt Duplex Receptacles 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Optional 240 Volt Duplex Receptacle 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE & TROUBLESHOOTING 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Routine Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Servicing Air Cleaner 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Fuel Filter And Sludge Drain Plug 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Adjusting Engine Speed 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Checking Battery Voltage Or Replacing Battery 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Jump-Starting Welding Generator 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Optional Remote Oil Filter 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Overload Protection 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Optional Spark Arrestor Inspection And Cleaning 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10. Troubleshooting 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAMS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − RUN-IN PROCEDURE 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Run-In Procedure Using Load Bank 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Run-In Procedure Using Resistance Grid 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − AUXILIARY POWER GUIDELINES 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. How Much Power Does Equipment Require? 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. How Much Power Can Generator Supply? 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Typical Connections To Supply Standby Power 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Selecting Extension Cord 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − PARTS LIST 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-1. Main Assembly 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-2. Generator 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-3. Panel, Front w/Components 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-4. Switch, Selector 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-5. Contact Board, Switch Selector 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-6. Switch Assembly & Rheostat 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-7. Contact Board, Switch Slope/Current 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Equipment 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-456 Page 1

SECTION 1 − SAFETY INFORMATION

mod1.1 2/93

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.

Learn the meaning of WARNING and CAUTION.

1 Safety Alert Symbol

2 Signal Word

WARNING means possible death

or serious injury can happen.

CAUTION means possible minor

injury or equipment damage can

happen.

3 Statement Of Hazard And Re-

sult

4 Safety Instructions To Avoid

Hazard

5 Hazard Symbol (If Available)

6 Safety Banner

Read safety blocks for each sym-

bol shown.

7 NOTE

Special instructions for best oper-

ation - not related to safety.

2

NOTE

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Disconnect input power before

installing or servicing.

WARNING

READ SAFETY BLOCKS at start of

Section 3-1 before proceeding.

WARNING

5

4

6

7

1 2

CAUTION

MOVING PARTS can injure.

• Keep away from moving parts.

• Keep all panels and covers closed

when operating.

3

Turn Off switch when using high frequency.

Figure 1-1. Safety Information

SECTION 2 − SPECIFICATIONS

Table 2-1. Welding Generator

Specification Description

Type Of Output Constant Current/Constant Voltage (CC/CV), Direct Current (DC)

Welding Processes Shielded Metal Arc (SMAW), And Gas Metal Arc Welding (GMAW)

Auxiliary Power Rating Single-Phase, 3 kVA/kW, 120 Volts AC, 60 HZ

Engine Teledyne-Continental TMD-27 Liquid-Cooled, Diesel Engine (See Engine Manual)

Engine Speed (No Load) Weld/Power Speed: 1850 rpm; Idle Speed: 1200 rpm

Coolant System Capacity 9 qt (8.5 L)

Fuel Tank Capacity 17.5 gal (66.2 L)

Overall Dimensions See Figure 3-2

Weight Net: 1940 lb (880 kg); Ship: 1980 lb (898 kg)

CC/DC Mode CV/DC Mode

Rated Weld Output 350 Amperes, 40 Volts At 100% Duty Cycle (See

Section 2-2)

400 Amperes, 36 Volts At 100% Duty Cycle (See

Section 2-2)

Amperage Ranges MIN-70 A, 60-110 A, 90-200 A, 125-275 A,

200 A-MAX

50 to 450 A

Open-Circuit Voltage Ranges 55-90 V 18-29 V, 21-35 V, 26-42 V, 34-55 V

Max. Open-Circuit Voltage 95 V 60 V

OM-456 Page 2

2-1. Volt-Ampere Curves

The volt-ampere curves show the

minimum and maximum voltage

and amperage output capabilities of

the welding generator. Curves of

other settings fall between the

curves shown.

rsb1.1 10/91 − SB-085 475-C / SB-085 455-C / SB-085 445-C / SB-086 131-C

A. For Min. Slope CV Mode

C. For Max. Slope CV Mode

B. For Med. Slope CV Mode

D. For CC Mode

Figure 2-1. Volt-Ampere Curves

OM-456 Page 3

2-2. Duty Cycle

CAUTION

WELDING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.

• Do not weld at rated load longer than shown below.

warn7.1 8/93

Duty Cycle is percentage of 10

minutes that unit can weld at

rated load without overheating.

Continuous Welding

sb1.1 8/93 − ST-053 214-B / ST-053 312-B

0

10

Minutes

100% Duty Cycle At 400 AmperesDefinition

Charts

A. For CC Mode B. For CV Mode

Figure 2-2. Duty Cycle

2-3. Fuel Consumption

The fuel consumption curve shows

typical fuel use under weld or power

loads.

rsb2.1 10/91 − SB-086 206-A

Figure 2-3. Fuel Consumption Curve

OM-456 Page 4

2-4. AC Auxiliary Power

The ac power curve shows the aux-

iliary power in amperes available at

the 120 and 240 volt receptacles.

rsb3.1 2/92 − SB-005 192-B

Figure 2-4. AC Power Curve For 120 And Optional 240 Volt Receptacles

SECTION 3 − INSTALLATION

3-1. Selecting A Location And Moving Welding Generator

WARNING

ENGINE EXHAUST GASES can kill.

• Do not breathe exhaust fumes.

• Use in open, well-ventilated areas, or vent exhaust

outside and away from building air intakes.

ENGINE EXHAUST SPARKS can cause

fire.

• Use only U.S. Forestry Department approved spark

arrestor and comply with all local, state, and federal

laws.

• A spark arrestor is mandatory in all National Forests

and in grass, brush, or forest covered lands in

California, Oregon, and Washington. Check with

state and local authorities in other areas.

• Properly maintain the spark arrestor.

• Stop engine and allow exhaust system to cool down

before servicing spark arrestor.

• Service spark arrestor away from flammables.

HOT ENGINE EXHAUST AND EXHAUST

PIPE can cause fires.

• Keep exhaust and pipe away from flammables.

FALLING EQUIPMENT can cause

serious personal injury and equipment

damage.

• Use lifting eye to lift unit only, NOT running gear, gas

cylinders, trailer, or any other heavy options,

accessories, or devices.

• Use equipment of adequate capacity to lift the unit.

TILTING OF TRAILER can result in

personal injury or equipment damage.

• Install unit properly on trailer (if applicable)

according to trailer manual.

rwarn1.1 3/93

OM-456 Page 5

rsb20.2 5/94 − Ref. ST-800 652 / ST-800 477 / ST-133 781-A

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks to

move unit.

3 Cross Member Support

If using lifting forks, lift only from end

with cross member support.

4 Trailer

Install unit on trailer according to

trailer manual.

Location And Airflow

OR

1

Movement

2

3

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

4

Figure 3-1. Movement And Location Of Welding Generator

Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.

NOTE

ST-158 403

B

A

C

Inches Millimeters

A 55-1/4 1403

B 25 635

C 74-3/4 1899

D 72 1829

E 69 1753

F 64-1/8 1629

G 57 1448

H 55 1397

J 40-1/16 1018

K 32-1/4 819

L 20-1/4 514

M 18-1/4 464

N 7-7/8 200

P2 51

Q 11/16 17

R 23 584

S 24-7/8 632

T 21/32 Dia. 17 Dia.

20 Holes 20 Holes

D

E

F

G

H

J

K

L

M

N

P

QR

S

T

Figure 3-2. Overall Dimensions And Base Mounting Hole Layout

OM-456 Page 6

Do not exceed operating angles while

running or engine damage will occur.

30°

S-0024-C

Figure 3-3. Maximum Welding Generator Operating Angles

3-2. Installing Muffler

rsb19.1* 5/92 − ST-158 449

Stop engine and allow to cool.

Open and secure right side door.

1 Muffler

2 Exhaust Pipe

Install muffler on pipe so outlet

faces rear of unit.

3 Clamp

Secure muffler to pipe with clamp.

Close door.

Do not blow exhaust toward

air cleaner or air intake.

1/2 in

Tools Needed:

1

2

3

Figure 3-4. Installing Muffler

OM-456 Page 7

3-3. Connecting The Battery

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

• Stop engine before disconnecting or connecting battery cables.

• Always wear a face shield and proper protective clothing when working on a battery.

• Do not allow tools to cause sparks when working on a battery.

rwarn2.1 9/91

Ref. ST-145 221-B / Ref. ST-138 751-C / Ref. S-0756-D

1 Engine Control Switch

Place switch in the Off position.

2 Screw

3 Battery Box Door

Remove screw to open door.

4 Positive (+) Battery Terminal

5 Positive (+) Battery Cable

Connect positive cable first.

6 Negative (−) Battery Terminal

7 Negative (−) Battery Cable

Connect negative cable last.

Close battery door.

If engine will not crank, check bat-

tery voltage according to Section

6-5.

Tools Needed:

1/2 in

1

3

2

−

+

5

7

4

6

Figure 3-5. Connecting The Battery

OM-456 Page 8

3-4. Engine Prestart Checks

ENGINE FUEL can cause fire or

explosion.

• Stop engine before fueling.

• Do not fuel while smoking or near sparks or flames.

• Do not overfill tank; clean up any spilled fuel.

USE OF GASOLINE will damage engine.

• Do not use gasoline.

Lack of lubrication in gasoline damages injector pump

and injectors.

REMOVE FUEL CAP SLOWLY; FUEL

SPRAY may cause injury; FUEL may be

under pressure.

• Turn fuel cap slowly and wait until hissing stops

before removing cap.

HOT PRESSURIZED COOLANT AND

STEAM can cause serious personal

injury.

• Let engine cool before removing radiator cap.

• Wear proper gloves, and cover cap area with rag

when removing radiator cap.

• Turn radiator cap slowly and wait until pressure is

gone before removing cap.

INCORRECT ENGINE TEMPERATURE

can damage engine.

• Do not run engine without a properly working 180° F

(80° C) thermostat and 7 psi (48 kPa) radiator cap.

Sludge and carbon can build up in engine if run cold.

Engine can be damaged if overheated.

WARNING

rwarn15.1 8/94

rsb4.4 8/94 − Ref. ST-158 437-A

FUEL

OIL

Full

3

4

Full

1/2 in

(13 mm)

Check all fluids daily. Engine must

be cold and on a level surface.

Add fresh fuel before starting

engine the first time (see

Figure 6-2).

1 Fuel Cap

Do not run out of fuel or air enters

fuel system and causes starting

problems.

2 Fuel Valve

Open valve (On position).

3 Oil Dipstick

4 Oil Fill Tube

If oil is not up to full mark, add oil

(see Figure 6-2).

5 Radiator Cap Door

Supplied coolant is mixture of water

and ethylene glycol base anti-

freeze. Add antifreeze if using unit

in temperatures below 0° F (−18°

C).

6 Exhaust Pipe

Follow break-in procedure in

engine manual.

If unburned fuel and oil collect in

exhaust pipe during break-in, see

Section 8.

Full

1

COOLANT

5

6

S-013 466-C

OFF

FUEL ON

2

Figure 3-6. Checking Fluid Levels

OM-456 Page 9

3-5. Generator Auxiliary Power System

A. Selecting Equipment

WARNING

ELECTRIC SHOCK can kill.

• Use only grounded or double insulated equipment.

1 Auxiliary Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

OR

2

Be sure equipment has this

symbol and/or wording.

3

1

Ref. ST-133 782-A / ST-800 577

1/2 in

Tools Needed:

Figure 3-7. Proper Equipment To Use

B. Grounding The Generator To A Truck Or Trailer Frame

S-0854

1 Generator Base

2 Metal Vehicle Frame

3 Equipment Grounding

Terminal

4 Grounding Cable

OR

1

2

Electrically bond generator

frame to vehicle frame by

metal-to-metal contact.

GND/PE

Use #10 AWG or

larger insulated

copper wire.

2

3 4

Figure 3-8. Grounding Methods

OM-456 Page 10

C. Grounding The Generator When Connecting To Home, Shop, Or Farm Wiring

rsb5.1 8/93 − ST-800 576

1 Equipment Grounding

Terminal

2 Grounding Cable

Use #10 AWG or larger insulated

copper wire.

3 Water Meter

4 Metal Water Pipe

5 Driven Ground Rod

Ground generator to system earth

ground if supplying power to a

premises (home, shop, farm) wiring

system − see Section 9.

2

4 or 5

OR

GND/PE

1 2

4

Use metal water pipe or driven ground rod or

other means as stated in electrical codes.

5

3

Figure 3-9. Grounding When Supplying Building Systems

3-6. Selecting And Preparing Weld Output Cables

sb6.5* 5/94 − S-0752

1 Weld Output Cable

Determine total cable length in weld

circuit and maximum welding am-

peres. Use Table 3-1 to select prop-

er cable size.

Use shortest cables possible.

Do not use damaged cables.

2 Terminal Lug

Use lugs of proper amperage

capacity and hole size for connect-

ing to work clamp, wire feeder or

electrode holder, and weld output

terminals.

3 Wire Feeder

4 Insulated Electrode Holder

Install according to manufacturer’s

instructions.

5 Work Clamp

Install onto work cable.

10 ft (3 m)

1

Total Cable

Length In Weld

Circuit = 20 ft (6 m)

10 ft (3 m)

For Example,

2

5

2

Tools Needed:

3 4

OR

Figure 3-10. Selecting And Preparing Weld Output Cables

OM-456 Page 11

Table 3-1. Weld Cable Size*

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Welding

Amperes

10 To 60%

Duty Cycle

60 Thru 100%

Duty Cycle

10 Thru 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D

3-7. Connecting To Weld Output Terminals

WARNING

ELECTRIC SHOCK can kill.

• Always wear dry insulating gloves.

• Do not touch live electrical parts.

• Stop engine before making any weld output connections.

• Do not use both Positive (+) output terminals at the same time.

• Both Positive (+) output terminals are electrically hot (energized) whenever the engine is running.

• Read Safety Precautions at beginning of this manual.

rwarn13.1* 2/92

Ref. ST-133 782-A

Open lower access door.

1 Weld Output Label

2 Negative (−) Weld Output Ter-

minal

3 Positive (+) GMAW Weld Out-

put Terminal

Provides CV (constant voltage)

output for GMAW welding.

4 Positive (+) SMAW Weld Out-

put Terminal

Provides CC (constant current)

output for SMAW welding.

For Direct Current Electrode Posi-

tive (DCEP), connect work cable to

− terminal and electrode holder or

wire feeder cable to proper +

terminal.

For Direct Current Electrode Nega-

tive (DCEN), reverse cable

connections.

Close access door.

Tools Needed:

3/8, 3/4 in

−

+

GMAW SMAW

POSITIVENEGATIVE

S-000 595-C

1

2

4

3

Use ONLY two weld output

terminals at a time.

Figure 3-11. Weld Output Connections

OM-456 Page 12

3-8. Remote A/V Receptacle Connections

Ref. ST-145 221-B

1 Remote A/V Receptacle RC3

2 Keyway

To connect remote amperage or

voltage control to this receptacle,

align keyway, insert plug, and turn

plug clockwise.

1

2

Figure 3-12. Remote A/V Receptacle Connections

3-9. Remote 14 Receptacle Or Terminal Strip Connections

A. Remote 14 Receptacle Connections

sb7.1 5/94 − ST-800 954 / Ref. S-0004-A / S-0750 / Ref. ST-141 127-B

1 Remote 14 Receptacle RC4

(See Table 3-2)

2 Keyway

3 Plug

4 Threaded Collar

To connect to receptacle, align

keyway, insert plug, and tighten

threaded collar.

3

4

OR

AJ

B

K

I

C

L

NH

D

M

G

E

F

1

2

3/8 in

Tools Needed:

Figure 3-13. Remote 14 Connections

Table 3-2. Remote 14 Socket Information

A 24 volts ac. Protected by circuit breaker CB3.

B Contact closure to A completes 24 volts ac contactor control circuit.

I 115 volts ac. Protected by circuit breaker CB4.

J Contact closure to I completes 115 volts ac contactor control circuit.

G Circuit common for 24 and 115 volts ac circuits.

K Chassis common.

Socket Information

*The remaining sockets are not used.

Socket*

OM-456 Page 13

B. Terminal Strip 1T Connections

WARNING

ELECTRIC SHOCK can kill; UNEXPECTED OUTPUT can cause serious injury.

• Do not touch live electrical parts.

• Stop engine before making any internal inspection or connections.

• Do not connect to Remote 14 receptacle and terminal strip at the same time.

Output (Contactor) can be energized from either the receptacle or terminal strip. Use only one remote control method.

Ref. ST-133 781-A / ST-136 872-A

Stop engine.

Remove plug from remote control

cord.

1 Right Front Panel

2 Terminal Strip Label

Remove panel.

3 Strain Relief

4 Terminal Strip 1T

Route cord through strain relief.

Connect leads to 1T using informa-

tion on label.

Install side panel, and close access

door.

Tools Needed:

3/8 in

A

B

G

I

J

K

24VAC 10A MAX

Circuit Common

115VAC 10A MAX

Equipment Ground

115VAC Contactor Control

Power SupplyExternal Device

1T

S-136 798

24VAC Contactor Control

24VAC

115VAC

W

CR

1

2

34

Rear Of

Front Panel

Figure 3-14. Terminal Strip 1T Connections

OM-456 Page 14

SECTION 4 − OPERATING THE WELDING GENERATOR

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Always wear dry insulating gloves.

• Insulate yourself from work and ground.

• Stop engine before installing or servicing.

• Keep all panels and covers securely in place.

WELDING can cause fire or explosion.

• Do not weld near flammable material.

• Watch for fire; keep extinguisher nearby.

• Do not locate unit over combustible surfaces.

• Do not weld on closed containers.

• Allow work and equipment to cool before handling.

ARC RAYS can burn eyes and skin;

NOISE can damage hearing.

• Wear welding helmet with correct shade of filter.

• Wear correct eye, ear, and body protection.

FUMES AND GASES can be hazardous.

• Keep your head out of the fumes.

• Ventilate area, or use breathing device.

• Read Material Safety Data Sheets (MSDSs) and

manufacturer’s instructions for material used.

ENGINE EXHAUST GASES can kill.

• Do not breathe exhaust fumes.

• Use in open, well-ventilated areas, or vent exhaust

outside and away from any building air intakes.

ENGINE FUEL can cause fire or explo-

sion.

• Stop engine before fueling.

• Do not fuel while smoking or near sparks or flames.

• Do not overfill tank; clean up any spilled fuel.

MOVING PARTS can cause injury.

• Keep away from moving parts such as fans, belts,

and rotors.

• Keep all doors, panels, covers, and guards closed

and securely in place.

MAGNETIC FIELDS FROM HIGH CUR-

RENTS can affect pacemaker operation.

• Pacemaker wearers keep away.

• Wearers should consult their doctor before going

near any welding operations.

See Safety Precautions at beginning of manual for ba-

sic welding safety information.

WARNING

rwarn5.1 10/91

Ref. ST-133 782-A

1 Open-Circuit Voltage Switch

2 Amperage Range Switch

3 Amperage/Voltage Adjustment

Control

4 Slope Switch

5 Magnetic Shutdown Switch

6 Engine Control Switch

7 Amperage/Voltage Control

Switch

8 Output (Contactor) Control

Switch

9 Engine Hour Meter

10 Ammeter

11 Voltmeter

12 Tachometer (Optional)

13 Engine Oil Pressure Gauge

(Optional)

14 Engine Temperature Gauge

(Optional)

15 Battery Light

16 Engine Temperature And Oil

Pressure Light

12 3

4

5

6

7

89101112

13

14

15

16

Figure 4-1. Controls

OM-456 Page 15

Wear the following while welding:

1 Dry, Insulating Gloves

2 Safety Glasses With Side

Shields

3 Welding Helmet With Correct

Shade Of Filter (See ANSI

Z49.1)

sb3.1 1/94

123

Figure 4-2. Safety Equipment

1 Work Clamp

Connect work clamp to a clean,

paint-free location on workpiece, as

close to weld area as possible.

Use wire brush or sandpaper to

clean metal at weld joint area. Use

chipping hammer to remove slag

after welding.

sb4.1 2/93

Tools Needed:

1

Figure 4-3. Work Clamp

CAUTION

ARCING can damage switch.

• Do not change Slope switch position while welding.

Arcing inside switch can damage contacts, causing switch to fail.

rwarn6.1* 2/93

1 Slope Switch

For GMAW, use switch to select

short-circuit current. The Min.

Slope position provides higher

short-circuit current than the Max.

Slope position (see Section 2-1).

For SMAW, place switch in SMAW

position.

1

Ref. ST-145 221-B

Figure 4-4. Slope Switch

OM-456 Page 16

CAUTION

ARCING can damage switch.

• Do not change Amperage Range switch or Open-Circuit Voltage switch position while welding.

Arcing inside switch can damage contacts, causing switch to fail.

rwarn6.1* 2/93

1 Open-Circuit Voltage Switch

For GMAW, use switch to select

open-circuit voltage range. For

SMAW, place switch in SMAW po-

sition.

2 Amperage Range Switch

Use switch to select SMAW weld

amperage range.

3 Amperage/Voltage Adjustment

Control

Use control to adjust amperage/

voltage within range selected by

Open-Circuit Voltage switch or Am-

perage Range switch. Numbers

around control are for reference

only.

1

2

3

Set Amperage Range And Open-Circuit Voltage Set Percentage

In Example:

Range = 90 to 200 A DC

Percentage Of Range = 50%

Weld Output = 145 A DC (50% of 90 to 200 A)

Weld Output = 145 A DCSet Slope

Example: Front Panel Amperage Control For SMAW

Figure 4-5. Amperage/Voltage Controls

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